Chemical industry

Oil refinery in Louisiana - an example of chemical industry

The chemical industry comprises the companies that produce industrial chemicals. Central to the modern world economy, it converts raw materials (oil, natural gas, air, water, metals, and minerals) into more than 70,000 different products.

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Product category breakdown

1928 《Future war and the German chemical industry》

Sales of the chemical business can be divided into a few broad categories, including basic chemicals (about 35 to 37 percent of the dollar output), life sciences (30 percent), specialty chemicals (20 to 25 percent) and consumer products (about 10 percent).

Basic chemicals

Basic chemicals, or "commodity chemicals" are a broad chemical category including polymers, bulk petrochemicals and intermediates, other derivatives and basic industrials, inorganic chemicals, and fertilizers. Typical growth rates for basic chemicals are about 0.5 to 0.7 times GDP. Product prices are generally less than fifty cents per pound.

Polymers, the largest revenue segment at about 33 percent of the basic chemicals dollar value, includes all categories of plastics and man-made fibers. The major markets for plastics are packaging, followed by home construction, containers, appliances, pipe, transportation, toys, and games.

• The largest-volume polymer product, polyethylene (PE), is used mainly in packaging films and other markets such as milk bottles, containers, and pipe.
• Polyvinyl chloride (PVC), another large-volume product, is principally used to make pipe for construction markets as well as siding and, to a much smaller extent, transportation and packaging materials.
• Polypropylene (PP), similar in volume to PVC, is used in markets ranging from packaging, appliances, and containers to clothing and carpeting.
• Polystyrene (PS), another large-volume plastic, is used principally for appliances and packaging as well as toys and recreation.
• The leading man-made fibers include polyester, nylon, polypropylene, and acrylics, with applications including apparel, home furnishings, and other industrial and consumer use.

The principal raw materials for polymers are bulk petrochemicals.

Chemicals in the bulk petrochemicals and intermediates are primarily made from liquefied petroleum gas (LPG), natural gas, and crude oil. Their sales volume is close to 30 percent of overall basic chemicals. Typical large-volume products include ethylene, propylene, benzene, toluene, xylenes, methanol, vinyl chloride monomer (VCM), styrene, butadiene, and ethylene oxide. These chemicals are the starting points for most polymers and other organic chemicals as well as much of the specialty chemicals category.

Other derivatives and basic industrials include synthetic rubber, surfactants, dyes and pigments, turpentine, resins, carbon black, explosives, and rubber products and contribute about 20 percent of the basic chemicals' external sales.

Inorganic chemicals (about 12 percent of the revenue output) make up the oldest of the chemical categories. Products include salt, chlorine, caustic soda, soda ash, acids (such as nitric acid, phosphoric acid, and sulfuric acid), titanium dioxide, and hydrogen peroxide.

Fertilizers are the smallest category (about 6 percent) and include phosphates, ammonia, and potash chemicals.

Life sciences

Life sciences (about 30 percent of the dollar output of the chemistry business) include differentiated chemical and biological substances, pharmaceuticals, diagnostics, animal health products, vitamins, and pesticides. While much smaller in volume than other chemical sectors, their products tend to have very high prices—over ten dollars per pound—growth rates of 1.5 to 6 times GDP, and research and development spending at 15 to 25 percent of sales. Life science products are usually produced with very high specifications and are closely scrutinized by government agencies such as the Food and Drug Administration. Pesticides, also called "crop protection chemicals", are about 10 percent of this category and include herbicides, insecticides, and fungicides.

Specialty chemicals

Specialty chemicals are a category of relatively high valued, rapidly growing chemicals with diverse end product markets. Typical growth rates are one to three times GDP with prices over a dollar per pound. They are generally characterized by their innovative aspects. Products are sold for what they can do rather than for what chemicals they contain. Products include electronic chemicals, industrial gases, adhesives and sealants as well as coatings, industrial and institutional cleaning chemicals, and catalysts. Coatings make up about 15 percent of specialty chemicals sales, with other products ranging from 10 to 13 percent. Specialty Chemicals are sometimes referred to as "fine chemicals"

Consumer products

Consumer products include direct product sale of chemicals such as soaps, detergents, and cosmetics. Typical growth rates are 0.8 to 1.0 times GDP.

Every year, the American Chemistry Council tabulates the U.S. production volume of the top 100 basic chemicals. In 2000, the aggregate production volume of the top 100 chemicals totalled 502 million tons, up from 397 million tons in 1990. Inorganic chemicals tend to be the largest volume, though much smaller in dollar revenue terms due to their low prices. The top 11 of the 100 chemicals in 2000 were sulfuric acid (44 million tons), nitrogen (34), ethylene (28), oxygen (27), lime (22), ammonia (17), propylene (16), polyethylene (15), chlorine (13), phosphoric acid (13) and diammonium phosphates (12).

Companies

The largest corporate producers worldwide, each with plants in numerous countries, include BASF, Bayer, Braskem, Celanese/Ticona, Degussa, Dow, DuPont, Eastman Chemical Company, ExxonMobil, INEOS, Mitsubishi, PPG Industries, SABIC and Shell, along with thousands of smaller firms.

In the U.S. there are 170 major chemical companies. They operate internationally with more than 2,800 facilities outside the U.S. and 1,700 foreign subsidiaries or affiliates operating. The U.S. chemical output is $750 billion a year. The U.S. industry records large trade surpluses and employs more than a million people in the United States alone. The chemical industry is also the second largest consumer of energy in manufacturing and spends over $5 billion annually on pollution abatement.

In Europe, especially Germany, the chemical, plastics and rubber sectors are among the largest industrial sectors. Together they generate about 3.2 million jobs in more than 60,000 companies. Since 2000 the chemical sector alone has represented 2/3 of the entire manufacturing trade surplus of the EU. The chemical sector accounts for 12% of the EU manufacturing industry's added value.

The chemical industry has shown rapid growth for more than fifty years. The fastest-growing areas have involved the manufacture of synthetic organic polymers used as plastics, fibres and elastomers. Historically and presently the chemical industry has been concentrated in three areas of the world, Western Europe, North America and Japan (the Triad). The European Community remains the largest producer area followed by the USA and Japan.

The traditional dominance of chemical production by the Triad countries is being challenged by changes in feedstock availability and price, labour cost, energy cost, differential rates of economic growth and environmental pressures. Instrumental in the changing structure of the global chemical industry has been the growth in China, India, Korea, the Middle East, South East Asia, Nigeria, and Brazil.

Technology

This is a process diagram of a turbine generator. Knowing how to design a sustainable process in which the system can withstand or manipulate process halting conditions such as; heat, friction, pressure, emissions, contaminants, is essential for engineers working to produce a sustainable process for use in the chemical industry.

As accepted by chemical engineers, the chemical industry involves the use of chemical processes such as chemical reactions and refining methods to produce a wide variety of solid, liquid, and gaseous materials. Most of these products are used in manufacture of other items, although a smaller number are used directly by consumers. Solvents, pesticides, lye, washing soda, and portland cement are a few examples of product used by consumers.

The industry includes manufacturers of inorganic- and organic-industrial chemicals, ceramic products, petrochemicals, agrochemicals, polymers and rubber (elastomers), oleochemicals (oils, fats, and waxes), explosives, fragrances and flavors. Examples of these products are shown in the Table below.

The novel chemical reactor reduces the amount of solvents used from 1000 litres to just 4 litres.

Product Type	Examples
inorganic industrial	ammonia, nitrogen, sodium hydroxide, sulfuric acid, nitric acid
organic industrial	acrylonitrile, phenol, ethylene oxide, urea
ceramic products	silica brick, frit
petrochemicals	ethylene, propylene, benzene, styrene
agrochemicals	fertilizers, insecticides, herbicides
polymers	polyethylene, Bakelite, polyester
elastomers	polyisoprene, neoprene, polyurethane
oleochemicals	lard, soybean oil, stearic acid
explosives	nitroglycerin, ammonium nitrate, nitrocellulose
fragrances and flavors	benzyl benzoate, coumarin, vanillin

Although the pharmaceutical industry is often considered a chemical industry , it has many different characteristics that puts it in a separate category. Other closely related industries include petroleum, glass, paint, ink, sealant, adhesive, and food processing manufacturers.

Chemical processes such as chemical reactions are used in chemical plants to form new substances in various types of reaction vessels. In many cases the reactions are conducted in special corrosion resistant equipment at elevated temperatures and pressures with the use of catalysts. The products of these reactions are separated using a variety of techniques including distillation especially fractional distillation, precipitation, crystallization, adsorption, filtration, sublimation, and drying.

The processes and product or products are usually tested during and after manufacture by dedicated instruments and on-site quality control laboratories to ensure safe operation and to assure that the product will meet required specifications. The products are packaged and delivered by many methods, including pipelines, tank-cars, and tank-trucks (for both solids and liquids), cylinders, drums, bottles, and boxes. Chemical companies often have a research and development laboratory for developing and testing products and processes. These facilities may include pilot plants, and such research facilities may be located at a site separate from the production plant(s).

History

Chandler (2005) argues the relative success or failure of American and European chemical companies is explained with reference to three themes: "barriers to entry," "strategic boundaries," and "limits to growth." He says successful chemical firms followed definite "paths of learning" whereby first movers and close followers created entry barriers to would-be rivals by building "integrated learning bases" (or organizational capabilities) which enabled them to develop, produce, distribute, and sell in local and then worldwide markets. Also they followed a "virtuous strategy" of reinvestment of retained earnings and growth through diversification, particularly to utilize "dynamic" scale and scope economies relating to new learning in launching "next generation" products.

Companies in the 21st century

The chemical industry includes large, medium, and small companies located worldwide. Companies with sales of chemical products greater than $10 billion dollars in fiscal year 2007 appear listed below. For some of these companies the chemical sales might represent only a portion of their total sales; (for example ExxonMobil's chemical sales covered only 8.7 percent of their total sales in 2005).

COMPANY, HEADQUARTERS	2007 Chemical Sales, billions	Rank	Country
BASF SE, Ludwigshafen, Germany	$65.3	1
Dow Chemical, Midland, Michigan, United States	$53.5	2
INEOS, Lyndhurst, UK	$43.6	3
LyondellBasell, Houston, Texas, United States	$42.8	4
Formosa Plastics, Taiwan	$31.9	5
DuPont, Wilmington, Delaware, United States	$28.5	6
Saudi Basic Industries Corporation, Riyadh, Saudi Arabia	$26.4	7
Bayer, AG, Leverkusen, Germany	$24.2	8
Mitsubishi Chemical, Tokyo, Japan	$22.2	9
Akzo Nobel/Imperial Chemical Industries(ICI), Amsterdam/London	$19.9	10
Air Liquide, Paris, France	$16.3	11
Sumitomo Chemical, Tokyo, Japan	$15.2	12
Evonik Industries, AG, Essen, Germany	$15.0	13
Mitsui Chemicals, Tokyo, Japan	$14.3	14
Asahi Kasei, Tokyo, Japan	$13.8	15
Toray Industries, Tokyo, Japan	$13.1	16
Chevron Phillips, The Woodlands, Texas, United States	$12.5	17
DSM NV, Heerlen, Netherlands	$12.1	18
PPG Industries, Pittsburgh, Pennsylvania, United States	$11.2	19
Shin-Etsu Chemical Co., Ltd., Tokyo, Japan	$11.1	20

Just as companies emerge as the main producers of the chemical industry, we can also look on a more global scale to how industrialized countries rank, with regards to the billions of dollars worth of production a country or region could export. Though the business of chemistry is worldwide in scope, the bulk of the world’s $3.7 trillion chemical output is accounted for by only a handful of industrialized nations. The United States alone produced $689 billion, 18.6 percent of the total world chemical output in 2008.

Global Chemical Shipments by Country/Region (billions of dollars)	1998	1999	2000	2001	2002	2003	2004	2005	2006	2008	2009
United States of America	416.7	420.3	449.2	438.4	462.5	487.7	540.9	610.9	657.7	664.1	689.3
Canada	21.1	21.8	25.0	24.8	25.8	30.5	36.2	40.2	43.7	45.4	47.4
Mexico	19.1	21.0	23.8	24.4	24.3	23.5	25.6	29.2	32.0	33.4	37.8
North America	456.9	463.1	498.0	487.6	512.6	541.7	602.7	680.3	733.4	742.8	774.6
Brazil	46.5	40.0	45.7	41.5	39.6	47.4	60.2	71.1	82.8	96.4	126.7
Other	59.2	58.1	60.8	63.4	58.6	62.9	69.9	77.2	84.6	89.5	102.1
Latin America	105.7	98.1	106.5	104.9	98.2	110.3	130.0	148.3	167.4	185.9	228.8
France	79.1	78.5	76.5	76.8	80.5	99.6	111.1	117.5	121.3	138.4	158.9
Germany	124.9	123.2	118.9	116.1	120.1	148.1	168.6	178.6	192.5	229.5	263.2
Italy	63.9	64.6	59.5	58.6	64.5	75.8	86.6	89.8	95.3	105.9	122.9
United Kingdom	70.3	70.1	66.8	66.4	69.9	77.3	91.3	95.2	107.8	118.2	123.4
Belgium	27.1	27.0	27.5	27.1	28.7	36.1	41.8	43.5	46.9	51.6	62.6
Ireland	16.9	20.1	22.6	22.9	29.1	32.3	33.9	34.9	37.5	46.0	54.8
Netherlands	29.7	29.4	31.3	30.6	32.2	40.1	49.0	52.7	59.2	67.9	81.7
Spain	31.0	30.8	30.8	31.9	33.4	42.0	48.9	52.7	56.7	63.7	74.8
Sweden	11.1	11.4	11.2	11.0	12.5	15.9	18.2	19.3	21.2	21.2	22.6
Switzerland	22.1	22.2	19.4	21.1	25.5	30.3	33.8	35.4	37.8	42.7	53.1
Other	27.1	26.8	25.9	26.4	27.9	33.5	38.6	42.9	46.2	50.3	58.9
Western Europe	503.1	504.0	490.4	488.8	524.4	630.9	721.9	762.7	822.4	935.4	1,076.8
Russia	23.8	24.6	27.4	29.1	30.3	33.4	37.5	40.9	53.1	63.0	77.6
Other	22.3	20.3	21.9	23.4	25.3	31.4	39.6	46.2	55.0	68.4	87.5
Central/Eastern Europe	46.1	44.9	49.3	52.5	55.6	64.8	77.1	87.1	108.0	131.3	165.1
Africa & Middle East	52.7	53.2	59.2	57.4	60.4	73.0	86.4	99.3	109.6	124.2	160.4
Japan	193.8	220.4	239.7	208.3	197.2	218.8	243.6	251.3	248.5	245.4	298.0
Asia-Pacific excluding Japan	215.2	241.9	276.1	271.5	300.5	369.1	463.9	567.5	668.8	795.5	993.2
China	80.9	87.8	103.6	111.0	126.5	159.9	205.0	269.0	331.4	406.4	549.4
India	30.7	35.3	35.3	32.5	33.5	40.8	53.3	63.6	72.5	91.1	98.2
Australia	11.3	12.1	11.2	10.8	11.3	14.9	17.0	18.7	19.1	22.8	27.1
Korea	39.3	45.5	56.3	50.4	54.9	64.4	78.7	91.9	103.4	116.7	133.2
Singapore	6.3	8.5	9.5	9.4	12.5	16.1	20.0	22.0	25.8	28.9	31.6
Taiwan	21.9	23.7	29.2	26.8	28.4	34.3	44.5	49.5	53.8	57.4	62.9
Other Asia/Pacific	24.8	29.1	30.9	30.8	33.3	38.8	45.5	52.9	62.9	72.2	90.8
Asia/Pacific	409.0	462.3	515.7	479.7	497.7	587.8	707.5	818.8	917.3	1041.0	1291.2
Total world shipments	1573.5	1625.5	1719.0	1670.9	1748.8	2008.5	2325.6	2596.4	2858.1	3160.7	3696.8

See also

• Chemical engineering
• Chemical Leasing
• Pharmaceutical industry
• Prices of elements and their compounds
• Responsible Care

References

• Fred Aftalion A History of the International Chemical Industry. University of Pennsylvania Press. 1991. online version
• E. N. Brandt. Growth Company: Dow Chemical's First Century. Michigan State University Press. xxii+ 650 pp. Appendices, Select bibliography and index. ISBN 0-87013-426-4. online review
• Alfred D. Chandler. Shaping the Industrial Century: The Remarkable Story of the Evolution of the Modern Chemical and Pharmaceutical Industries. Harvard University Press, 2005. 366 pp. ISBN 0-674-01720-X. chapters 3-6 deal with DuPont, Dow Chemicals, Monsanto, American Cyanamid, Union Carbide, and Allied in USA; and European chemical producers, Bayer, Farben, and ICI.
• Micheal McCoy, et al., "Facts & Figures of the Chemical Industry", Chemical & Engineering News, 84(29), July 10, 2006, pp. 35–72.
• Shreve, R. Norris, and Joseph A. Brink Jr. The Chemical Process Industries. 4th ed. New York: McGraw Hill, 1977.